Lamination of apertured or non-apertured three-dimensional films to apertured or non-apertured three-dimensional and/or flat films

ABSTRACT

The present invention provides an improved method for laminating a first three-dimensional apertured or non-apertured film material to a second flat or three-dimensional apertured or non-apertured film material utilizing the heat generated by the extrusion of the first and/or second materials and the films produced thereby.

This is a divisional of application Ser. No. 08/467,837 filed on Jun. 6,1995, now U.S. Pat. No. 5,698,054 which is a divisional of applicationSer. No. 08/286,475 filed on Aug. 5, 1994, now U.S. Pat. No. 5,635,275.

TECHNICAL FIELD

The present invention relates to the application or lamination of afirst film material onto a second material utilizing the heat generatedby extrusion of the first and/or second film materials. The presentinvention is especially useful in laminating an apertured film to anon-apertured three-dimensional or formed film. The present invention isalso especially useful for laminating a three-dimensional non-aperturedfilm to another three-dimensional non-apertured film.

BACKGROUND OF THE INVENTION

Many types of substrates including paper, non-woven laminates, foils,films, sheeting wood and other materials have been coated using anextrusion coating method. The extrusion coating process generallyincludes an extruder slot (cast) die mounted in a position above thesubstrate to be coated.

In the processes where nip rolls are utilized to apply a coatingmaterial to a substrate, the nip rolls add pressure to the substrate andcoating material at the interface. However, the nip pressure used inextrusion coating technology causes distortion of the coating materialand the substrate at the nip interface.

Previous attempts to laminate a three-dimensional material onto thinfilm materials which are particularly sensitive to excessive thermalloads have not met with success. In particular, the application of athree-dimensional apertured or non-apertured material to anotherthree-dimensional apertured or non-apertured material has beenespecially difficult to achieve. In such cases, there must be sufficientthermal energy to cause the first three-dimensional non-apertured filmmaterial and the second three-dimensional non-apertured film material tomelt and fuse together. Often these materials do not have sufficientmass to resist distortion under the required thermal load necessary toachieve a good bond between the film materials.

It is therefore an object of the present invention to provide animproved method for laminating a three-dimensional apertured ornon-apertured film material to a flat or three-dimensional apertured ornon-apertured film material.

It is another object of the present invention to provide an improvedcomposite laminated film comprising a three-dimensional apertured ornon-apertured film material laminated to a flat or three-dimensionalapertured or non-apertured film material.

It is still another object of the present invention to provide anarticle suitable for use as a disposable absorbent product such asdiapers, catamenial pads, surgical dressings and the like.

DISCLOSURE OF THE INVENTION

The present invention relates, in part, to a method for producing alaminated film having at least one three-dimensional apertured ornon-apertured film material laminated to at least one flat orthree-dimensional apertured or non-apertured film material and the filmsproduced thereby.

In order to have a thermoplastic material adhere or bond to anothermaterial, at least one of the materials must be supplied at asufficiently elevated temperature at a point of interface. The interfaceis the point at which the two materials come into contact with eachother. The temperature must be sufficiently elevated so that there issufficient thermal energy supplied at the point of interface. Theelevated temperature causes at least one of the following: melting andfusing of each of the materials together to form a bond, a chemicalreaction of one material with the other material to form a bond, ormelting of one material on the other material (non-melted) to form acohesive bond.

It is important to understand that since the viscosity of fluidscorrelates to the temperature of the fluids, the higher the temperature,the less viscous the fluid. Therefore, maintaining a high temperature(i.e., low viscosity) as one material contacts the other material isimportant. This maintenance of thermal energy as, and after, thematerials contact each other is controlled by two parameters of thermaldynamics, i.e., temperature and mass. At least one material must besupplied at a sufficiently elevated temperature and at a sufficient massin order to achieve a good bond. The materials being laminated togethermust be maintained at that sufficiently elevated temperature for asufficient time for the bond to form.

Polymers, and in particular thermoplastic polymers useful for laminatingto other thermoplastic or non-thermoplastic materials, have well-definedupper limits of temperature which can be manipulated before degradationof the polymer occurs. The well-defined thermal degradation limit of thepolymer necessarily controls the amount of heat supplied to thelamination process. The other parameter which can be controlled is themass of the materials being laminated together. Generally, the mass iscontrolled by regulating the thicknesses of the materials. In variousextrusion applications, it is desired to laminate a thin material toanother material. However, if too thin a layer is laminated, the layerquickly loses heat and cools too quickly. Without sufficient heat, thelow mass of the laminating material does not bond to the other material.Therefore, the lamination of one material to another material is limitedby the parameters of mass and temperature of the materials and by thelength of time at which the materials are maintained at the propertemperature.

The thermal requirements of the lamination process are further affectedif both materials are thermally sensitive materials. The amount ofthermal energy applied to the thermally sensitive materials isnecessarily limited by the amount of thermal energy the materialssubstrate can tolerate without being damaged. This is especially truefor a material which is a three-dimensional polymeric film havingmicroscopic protuberances (either open or closed). In applications wherethe microscopic protuberances have been opened or exploded such thatthere are apertures in the film, the thickness (and mass) of the film atthe open ends of the protuberances is further reduced. The thinness ofthe open ends of the protuberances results in a film material having acloth-like or silky tactile effect which is desired in many filmapplications. However, these microscopic film protuberances (either openor closed) are sensitive to temperature and have the lowest mass pointof the polymeric film and, as such, are the most critical to protect.While it would be desirable to laminate another thermoplastic ornon-thermoplastic material to such type of three-dimensionalthermoplastic film material, various difficulties occur when using thecurrently known coating technologies. In particular, both the thermalenergy of the known extrusion coating systems and the compressive energyof the nip roll systems have, until the present invention, made itvirtually impossible to achieve good bonding strength between themicroscopic protuberance-filled three-dimensional material and anymaterial laminated thereto without causing the destruction of themicroscopic protuberances.

It is important that the microprotuberances not be crushed or destroyedduring lamination of the three-dimensional film material to another filmmaterial. It is also important that any temperatures and/or pressuresapplied during the lamination process not cause the film materials beinglaminated together to be destroyed.

According to one embodiment of the present invention, a firstthermoplastic material is extruded onto a film forming screen having atop surface and a bottom surface and having a plurality of perforationsextending through the screen. A pressure differential is applied to aportion of the bottom surface of the film forming screen such thatportions of the extruded film material are drawn into the perforationsin the screen. The pressure differential pulls the portions of filmmaterial into the perforations in the screen and a plurality ofthree-dimensional microprotuberances are formed. If the pressuredifferential is sufficiently great, the microprotuberances are rupturedsuch that apertures are formed in the film. In other embodiments, thepressure differential is controlled such that no apertures are formed.The microprotuberances can have any combination of shapes; for example,the microprotuberances can be circular, hexagonal, quadrangular and thelike. Likewise, the depth and width of the apertures can greatly vary,depending on the thickness by weight of the film material.

A second material is laminated to the first thermoplastic film. Incertain embodiments, the second material comprises a three-dimensionalapertured material wherein the second material is laminated to the firstmaterial at a point prior to the formation of the microprotuberances inthe first material. In other embodiments, the second thermoplasticmaterial comprises a non-apertured flat or three-dimensional formed filmwherein the second material is laminated to the first material at apoint after formation of the microprotuberances in the first filmmaterial.

According to the present invention, various thermoplastic films aresuitable for use as either first material and/or the second material.Useful films include such films as polyethylene, polypropylene, ethylenevinyl acetate and other such polymeric materials. It is to be understoodthat the second material can also be a non-thermoplastic material suchas paper, tissue or foil. It is to be understood that either or both ofthe films to be laminated can include other ingredients such assurfactants to modify the film's surface energy. In such embodiments,these surfactants allow control of fluid flow onto or through thelaminate material. It is further to be understood that the first and/orsecond materials can comprise more than one layer. In particular, thefilm materials can be coextruded materials. Each layer of the coextrudedmaterial can have different properties which enhance lamination of thefirst material to the second material and/or provide other advantages tothe laminate film.

It is to be understood that each three-dimensional film has a planarsurface and a three-dimensional surface. According to the presentinvention, either the planar surface or the three-dimensional surface ofthe first material can be laminated to either the planar surface or thethree-dimensional surface of the second material. In one preferredembodiment, a thermally sensitive three-dimensional apertured film canbe laminated to a thermally sensitive three-dimensional non-aperturedfilm such that there is good bond strength between the apertured filmand the non-apertured film without causing thermal distortion or damageto the microprotuberances of either film.

It is also to be understood that the first film material and the secondfilm material can comprise more than one layer of material. In aparticularly preferred embodiment, a composite laminate film comprises afirst non-apertured three-dimensional film having a planar side and athree-dimensional side and a second non-apertured three-dimensional filmhaving a planar side and a three-dimensional side, wherein thethree-dimensional side of the second non-apertured film is laminated tothe planar side of the first non-apertured film. The composite filmfurther has a nonwoven layer comprised of a substantially liquidpervious fibrous materials adjacent the planar side of the secondnon-apertured film.

Thus, composite articles of the present invention provide highlydesirable liquid impervious or liquid pervious characteristics and alsoprovide the advantage of the desired tactile suede or cloth-likeproperties to the article produced with such films.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a simplified cross-sectional schematic illustration of oneprocess for laminating a material B onto one side of a material A.

FIG. 1A is a greatly enlarged cross-sectional illustration of the gaparea shown in FIG. 1.

FIG. 2 is a simplified cross-sectional schematic illustration of anotherprocess for laminating a material B onto one side of a material A.

FIG. 2A is a greatly enlarged cross-sectional illustration of the gaparea shown in FIG. 2.

FIG. 3 is a simplified, greatly enlarged cross-sectional illustration ofone embodiment of a composite film material comprising athree-dimensional apertured film having a planar side and athree-dimensional side, wherein the three-dimensional side of theapertured film is laminated to a planar side of a three-dimensionalnon-apertured film and a nonwoven material is laminated to the planarside of the apertured film.

FIG. 4 is a simplified greatly enlarged cross-sectional illustration ofanother embodiment of a composite film material comprising athree-dimensional apertured film having a planar side and athree-dimensional side, wherein the planar side of the apertured film islaminated to a planar side of a three-dimensional non-apertured film.

FIG. 5 is a simplified greatly enlarged cross-sectional illustration ofanother embodiment of a composite film material comprising a firstthree-dimensional non-apertured film having a planar side of the firstfilm and a three-dimensional side, wherein the planar side of the firstfilm is laminated to a planar side of a second three-dimensionalnon-apertured film.

FIG. 6 is a simplified greatly enlarged cross-sectional illustration ofanother embodiment of a composite film material comprising a flat orplanar material laminated to a planar side of a three-dimensionalnon-apertured film.

FIG. 7 is a simplified greatly enlarged cross-sectional illustration ofanother embodiment of a composite film material comprising a flat orplanar thermoplastic film laminated to a planar side of athree-dimensional apertured film.

FIG. 8 is a simplified greatly enlarged cross-sectional illustration ofanother embodiment of a composite film material comprising a firstthree-dimensional apertured film having a planar side and athree-dimensional side, wherein the three dimensional side of the firstfilm is laminated to a planar side of a second three-dimensionalapertured film.

FIG. 9 is a simplified greatly enlarged cross-sectional illustration ofanother embodiment of a composite film material comprising a firstthree-dimensional apertured film having a planar side and athree-dimensional side, wherein the three dimensional side of the firstfilm is laminated to a planar side of a second three-dimensionalapertured film.

FIG. 10 is a simplified greatly enlarged cross-sectional illustration ofanother embodiment of a composite film material comprising a firstthree-dimensional apertured film having a planar side and athree-dimensional side, wherein the planar side of the first film islaminated to a planar side of a three-dimensional apertured film.

FIG. 11 is a simplified greatly enlarged cross-sectional illustration ofanother embodiment of a composite film material comprising athree-dimensional non-apertured film having a planar side and athree-dimensional side, wherein the three-dimensional side of thenon-apertured film is laminated to a planar side of a coextrudedthree-dimensional non-apertured film.

FIG. 12 is a simplified greatly enlarged cross-sectional illustration ofanother embodiment of a composite film material comprising a firstthree-dimensional non-apertured film material having a planar side and athree-dimensional side, wherein the three-dimensional side of the firstfilm is laminated to a three-dimensional side of a secondthree-dimensional non-apertured film and wherein a nonwoven material islaminated to the planar side of the second material.

BEST MODE OF CARRYING OUT INVENTION

One embodiment of the present invention is generally shown in FIGS. 1and 1A. A first material A is dispensed from a slot die 10 having anaperture 12 onto a moving member 20. It is to be understood that themoving member can be a cylindrical screen or a conveyor belt typeapparatus or other moving member. For ease of illustration, the movingmember is depicted herein as a cylindrical screen. In preferredembodiments of the present invention, the aperture 12 is spaced at apredetermined distance from the screen 20. The screen 20 has a surface22 which is highly perforated with perforations 24 (seen in FIG. 1A)shown in a greatly enlarged manner for ease of illustration. Theperforations 24 extend through the surface 22 to allow fluid such as airto pass through the surface 22 of the screen 20. A vacuum chamber 26,preferably located within the screen 20, is utilized to create apressure differential.

The material A, being dispensed onto the screen 20, has a top surface 16and a bottom surface 18. The vacuum chamber 26 creates a pressuredifferential between the top surface 16 and the bottom surface 18 of thematerial A. The pressure differential causes portions of the material Ato be pulled into the perforations 24 in the screen 20. The pressuredifferential is sufficient to produce three-dimensionalmicroprotuberances 19 on the bottom surface 18 of the material A, asbest seen in FIG. 1A. In various embodiments, the pressure differentialis sufficient to cause the microprotuberances 19 to rupture, thusforming an apertured material A. In other embodiments, the pressuredifferential is regulated such that microprotuberances 19 are formedextending from the bottom surface 18 of material A without any rupturingof the microprotuberances 19.

The vacuum chamber 26 generally comprises a leading edge 28 and atrailing edge 29. The microprotuberances 19 are generally formed in anarea adjacent the leading edge 28 of the vacuum chamber 26. As the filmA moves towards the trailing edge 29, the vacuum pressure differentialcools and sets the microprotuberances 19 in the film A. The widthbetween the leading edge 28 and trailing edge 29 can be varied such thatthe film spends greater or less time under the pressure differential.The length of time also helps hold the microprotuberance formation suchthat the film cools and "sets" or embosses the microprotuberances in thefilm.

A second material B is laminated onto the top surface 16 of the film A.The material B generally has a top surface 32 and a bottom surface 34.In the embodiment shown, the material B is generally dispensed from aroll 35. It should be understood that the material B can be supplied inother methods, including directly from a film forming process (notshown). The material B shown in FIGS. 1 and 1A is an aperturedthree-dimensional thermoplastic material having a plurality of rupturedmicroprotuberances 37 extending from the bottom surface 34 of thematerial B. However, it should be understood that the material B can bea flat or non-apertured three-dimensional thermoplastic ornon-thermoplastic film.

In the embodiment shown in FIGS. 1 and 1A, the material B is laminatedonto the top surface 16 of the film A at a point prior to the formationof microprotuberances of the material A. The material B is passed overat least one roll 36 and brought into close proximity to the material A.The proximity of the roll 36 to the film material A can be varied. Theplacement of the roll 36 can be as close to the die 10 as shown inphantom as roll 36'. Alternatively, the roll 36 can be placed furtherdownstream as shown in phantom as roll 36". The film material B can bebrought into contact with film A anywhere along the surface of film A.In certain preferred embodiments of the present invention, the roll 36is spaced at a predetermined distance from the surface 22 of the screen20. A gap 38 generally defines the distance between the roll 36 and thescreen 20. The preferred gap 38 between the roll 36 and screen 22 isdetermined by the effective thicknesses of each of the materials A and Bbeing laminated together. In certain embodiments, the length of the gap38 is much greater than the effective thicknesses of each material A andB. In certain other embodiments, the length of the gap 38 is slightlyless than the effective thicknesses of each material A and material B.As materials A and B pass through the gap 38, the effective thicknessesof the materials A and B are reduced somewhat. In certain embodiments,the length of the gap 38 can range from about 50% to about 99% of theeffective thicknesses of the material A and material B being laminatedtogether. In various embodiments, the gap 38 is about 75% to about 95%of the effective thicknesses of each material A and material B.

As the microprotuberances 37 of material B are brought into contact withthe top surface 16 of material A, significant bonding occurs betweenmaterial A and material B. In the embodiment shown in FIG. 1, thematerial B is laminated to the top surface 16 of the material A at aninterface point 40 just prior to applying the pressure differential tothe material A in order to form the microprotuberances in the materialA. It is to be understood that the point of interface between material Aand material B is dependent upon a number of factors including thetemperatures of materials A and B, the chemical composition of thematerials A and B, the physical characteristics of the materials A and B(such as whether flat or three-dimensional, apertured or non-apertured)and the like. Thus, material B can be brought into contact with materialA at various points along the stream of the extruded material A, asshown by roll 36' and roll 36".

The surface temperature of the film A being extruded is within or higherthan the melting range temperature of the thermoplastic material makingup the laminating surface of the film B. Material A is extruded at apredetermined elevated temperature such that the microprotuberances 19can be readily formed in the material A. The elevated temperature of thematerial A provides heat energy at the point of interface 40 such thatthe apertures 37 on the bottom surface 34 of material B willsignificantly bond to the top surface 16 of the material A. It is to beunderstood that the roll 36 can either be heated or cooled to provide apredetermined amount of heat energy as material B is being laminatedonto material A. In certain embodiments, the material B can be preheatedby a heating means 42 to aid in raising the temperature of material Bsuch that material B readily bonds to material A. In still otherembodiments, not shown, successive portions of the material B can bepassed adjacent the extruded material A such that heat radiating frommaterial A preheats the material B. In such embodiments, it iscontemplated that roll 36' can be spaced apart from the top surface 16of material A and that roll 36 can actually bring material B intocontact with material A.

In certain embodiments as materials A and B pass through the gap 38,both materials A and B can be compressed somewhat such that themicroprotuberances 37 on material B are slightly distorted and arebonded or laminated to the top surface 16 of the material A. In certainembodiments as the materials A and B pass through the gap 38, thepreferred amount of pressure is slight, yet sufficient to achievelamination without greatly distorting the films or causing themicroprotuberances 37 to collapse or melt together. According to thepresent invention, the portions of the material B which are in contactwith the film material A reach a fusion, melting or softening pointtemperature such that the material B readily bonds or laminates tomaterial A.

In other embodiments, no pressure is applied to the material A andmaterial B being laminated together. The materials A and B are broughtinto contact with each other at the gap 38 and by mere contact with eachother, the film materials A and B are laminated together. In addition,the chemical composition of each film material determines its tackinessor adhesiveness to other materials. The gap between the roll 36 and thescreen 20 can be adjusted to account for such differences orsimilarities between the polymers used in the laminating film materials.

Another embodiment of the present invention is generally shown in FIGS.2 and 2A. A first material A' is dispensed from a slot die 50 having anaperture 52 onto a screen 60. In preferred embodiments of the presentinvention, the aperture 52 is spaced at a predetermined distance fromthe screen 60. The screen 60 has a surface 62 which is highly perforatedwith perforations 64 (seen in FIG. 2A) shown in a greatly enlargedmanner for ease of illustration. The perforations 64 extend through thesurface 62 to allow fluid such as air to pass through the surface 62 ofthe screen 60. A vacuum chamber 66, preferably located within the screen60, is utilized to create a pressure differential.

The material A', being dispensed onto the screen 60, has a top surface56 and a bottom surface 58. The vacuum chamber 66 creates a pressuredifferential between the top surface 56 and the bottom surface 58 of thematerial A'. The pressure differential causes portions of the materialA' to be pulled into the perforations 64 in the screen 60. The pressuredifferential is sufficient to produce three-dimensionalmicroprotuberances 59 on the bottom surface 58 of the material A', asbest seen in FIG. 2A. In various embodiments, the pressure differentialis sufficient to cause the microprotuberances 59 to rupture, thusforming an apertured material A'. In other embodiments, the pressuredifferential is regulated such that microprotuberances 59 are formedextending from the bottom surface 58 of material A' without anyrupturing of the microprotuberances 59.

The vacuum chamber 66 generally comprises a leading edge 68 and atrailing edge 69. The microprotuberances are generally formed in an areaadjacent the leading edge 68 of the vacuum chamber 66. As the film A'moves towards the trailing edge 69, the vacuum pressure differentialcools and sets the microprotuberances 59 in the film A'. The widthbetween the leading edge 28 and the trailing edge 29 can be varied.

A second material B' is laminated onto the top surface 56 of the filmA'. The material B' generally has a top surface 72 and a bottom surface74. In the embodiment shown, the material B' is generally dispensed froma roll 75. It should be understood that the material B' can be suppliedin other methods, including directly from a film forming process (notshown). The material B' shown in FIGS. 2 and 2A is non-aperturedthree-dimensional thermoplastic or non-thermoplastic material having aplurality of microprotuberances 77 extending from the bottom surface 74of the material B'. However, it should be understood that the materialB' can be a flat or other non-apertured three-dimensional thermoplasticor non-thermoplastic film. In the embodiments shown in FIGS. 2 and 2A,the material B' is laminated onto the top surface 56 of the film A' at apoint after the microprotuberances 59 are formed in the material A'. Thematerial B' is passed over a roll 76 and brought into close proximity tothe material A'. In preferred embodiments of the present invention, theroll 76 is spaced at a predetermined distance from the surface 62 of thescreen 60. A gap 78 generally defines the distance between the roll 76and the screen 60. The preferred gap 78 between the roll 76 and screen60 is determined by the effective thicknesses of each of the materialsA' and B' being laminated together. It is to be understood, however,that in certain other embodiments, the gap 78 is greater than theeffective thickness of the materials A and B. In certain otherembodiments, the length of the gap 78 is slightly less than theeffective thicknesses of each material A' and material B'. As films A'and B' pass through the gap 78, the effective thicknesses of thematerials are reduced somewhat. In certain embodiments, the length ofthe gap 78 can range from about 50% to about 99% of the effectivethicknesses of the material A' and material B' being laminated together.In various embodiments, the gap 78 is about 75% to about 95% of theeffective thickness of each material A' and material B'. As themicroprotuberances 59 of material B' are brought into contact with thetop surface 56 of material A', significant bonding occurs betweenmaterial A' and material B'.

In the embodiment shown in FIG. 2, the material B' is laminated to thetop surface 56 of the material A' at an interface point 80 after theperforations are formed in material A'. Material A' is extruded at apredetermined elevated temperature such that the microprotuberances 59can be formed and set in the material A. The elevated temperature of thematerial A' provides heat energy such that the microprotuberances 77 onthe bottom surface 74 of material B' will significantly bond to the topsurface 56 of the material A'. It is to be understood that the roll 76can either be heated or cooled to provide a predetermined amount of heatenergy as material B' is being laminated onto material A'. In addition,a heating means 82 can preheat the material B'.

In certain embodiments, as materials A' and B' pass through the gap 78,both materials A' and B' are compressed somewhat such that themicroprotuberances 77 on material B' are slightly distorted and arebonded or laminated to the top surface 56 of the material A'. As thematerials A' and B' pass through the gap 78, the preferred amount ofpressure is slight, yet sufficient to achieve lamination without greatlydistorting the films or causing the microprotuberances 77 to collapse ormelt together. As discussed above with respect to FIGS. 1 and 1A, incertain other embodiments, no pressure is applied at the point ofinterface and bonding occurs upon contact of material A' with materialB'.

It should be understood that the roll 76 can be adjacent the trailingedge 69 of the vacuum chamber 66 or alternatively, the roll 76 can beplaced downstream beyond the trailing edge 69 of the vacuum chamber 66.The position of the roll 76 is determined, in part, by the temperatureof the material A' and material B'. In addition, the gap 80 can beadjusted to conform to the relative effective thicknesses of the films.

Various embodiments of the present invention are shown in FIGS. 3-12. Itis to be understood, however, that other combinations of laminating onefilm to another film are within the scope of the present invention. Inparticular, the film material A and film material B can comprisemulti-layer structures.

FIG. 3 shows a three-dimensional composite laminate film 90 whichgenerally comprises a non-apertured three-dimensional film 92 having aplanar surface 94 and a three-dimensional surface 96 having a pluralityof microprotuberances 98 depending therefrom. The composite film 90further comprises an apertured three-dimensional film 102 having aplanar surface 104 and a three-dimensional surface 106 which defines aplurality of apertures 108 extending therethrough. The three-dimensionalsurface 106 of the apertured film 102 is laminated to the planar surface94 of the non-apertured film 92. The composite film 90 further comprisesa nonwoven material 110 having an upper surface 112 and a lower surface114. The lower surface 114 is laminated to the planar surface 104 of theapertured film 102. It is to be understood that this embodiment can bemade without the nonwoven material 110 adhered thereto.

FIG. 4 shows a further embodiment of the present invention comprising acomposite laminate film 120 comprising a three-dimensional non-aperturedfilm 122 having a planar surface 124 and a three-dimensional surface 126having a plurality of microprotuberances 128 extending therefrom. Thecomposite film 120 further comprises a three-dimensional apertured film132 having a planar surface 134 and a three-dimensional surface 136which defines a plurality of apertures 138 extending therethrough. Theplanar surface 134 of the three-dimensional apertured film 132 islaminated to the planar surface 124 of the non-apertured film 122. Thecomposite material 120 thus has the planar surfaces 124 and 134laminated together.

FIG. 5 shows a further composite laminate film 140 comprising a firstthree-dimensional non-apertured film 142 having a planar surface 144 anda three-dimensional surface 146 having a plurality of microprotuberances148 extending therefrom. The composite film 140 further comprises asecond three-dimensional non-apertured film 152 having a planar surface154 and a three-dimensional surface 156 having a plurality ofmicroprotuberances 158 extending therefrom. The planar surface 154 ofthe second non-apertured film 152 is laminated to the planar surface 144of the first non-apertured film 142. The planar surfaces 144 and 154 arelaminated together.

FIG. 6 shows a further composite laminate film 160 comprising athree-dimensional non-apertured film 162 having a planar surface 164 anda three-dimensional surface 166 having a plurality of microprotuberances168 extending therefrom. The composite film 160 further comprises arelatively planar or flat film 170 having a top surface 172 and a bottomsurface 174. The planar surface 164 of the non-apertured film 162 islaminated to the bottom surface 174 of the film 170.

FIG. 7 shows a further composite laminate material 180 comprising athree-dimensional apertured film 182 having a planar surface 184 and athree-dimensional surface 186 which defines a plurality of apertures 188extending therethrough. A relatively planar or flat film 190 having aupper surface 192 and a lower surface 194 is laminated to thethree-dimensional apertured film 182 such that the planar surface 184and lower surface 194 are laminated together.

FIG. 8 shows a further composite laminate material 200 comprising afirst three-dimensional apertured film 202 having a planar surface 204and a three-dimensional surface 206 which defines a plurality ofapertures 208 having a first predetermined size, which apertures 208extend through the film 202. The composite film 200 further comprises asecond three-dimensional apertured film 212 having a planar surface 214and a three-dimensional surface 216 which defines a plurality ofapertures 218 having a second predetermined size, which apertures 218extend through the film 212. The three-dimensional surface 216 of thesecond film is laminated to the planar surface 204 of the firstapertured film 202. In the embodiment shown in FIG. 8, themicroapertured film 202 has smaller apertures 208 than the apertures 218of the film 212.

FIG. 9 shows a further composite laminate material 220, wherein asmaller apertured film is laminated to a larger apertured film. The film220 comprises a first three-dimensional apertured film 222 having aplanar surface 224 and a three-dimensional surface 226 which defines aplurality of apertures 228 extending therethrough. The composite film220 further comprises a second three-dimensional apertured film 232having a planar surface 234 and a three-dimensional surface 236 whichdefines a plurality of apertures 238 extending therethrough. Thethree-dimensional surface 236 of the second film is laminated to theplanar surface 224 of the first film 220.

FIG. 10 shows a further composite laminate film 240 comprising a firstthree-dimensional apertured film 242 having a planar surface 244 and athree-dimensional surface 246 which defines a plurality of apertures 248extending therethrough. The composite film 240 comprises a secondthree-dimensional apertured film 252 having a planar surface 254 and athree-dimensional surface 256 which defines a plurality of apertures 258extending therethrough. The planar surface 254 of the second film 252 islaminated to the planar surface 244 of the first film 242.

FIG. 11 shows a further composite material 260 comprising athree-dimensional coextruded non-apertured film 262 having a planarsurface 264 and a three-dimensional surface 266 having a plurality ofmicroprotuberances 268 extending therefrom. The film 262 is a coextrudedmaterial having a first layer 263 and a second layer 265. The layer 263can have physical properties or melt temperature properties which allowthe film 262 to readily laminate to a film 272. The bottom layer 265 canprovide other properties such as strength and/or high meltcharacteristics to the composite material 260. The composite material260 further comprises the second three-dimensional non-apertured film272 having a planar surface 274 and a three-dimensional surface 276having a plurality of microprotuberances 278 extending therefrom. Thethree-dimensional surface 276 is laminated to the planar surface 264 ofthe film 262.

FIG. 12 shows a further composite material 280 comprising a firstthree-dimensional non-apertured film 282 having a planar surface 284 anda three-dimensional surface 286 having a plurality of microprotuberances288 extending therefrom. The composite film 280 further comprises asecond three-dimensional non-apertured film 292 having a planar surface294 and a three-dimensional surface 296 which defines a plurality ofmicroprotuberances 298 extending therefrom. The three-dimensionalsurface 298 of the second film 292 is laminated to the planar surface284 of the first film 282. The composite film 280 further comprises anonwoven material 300 having an upper surface 302 and a lower surface304. The lower surface 304 is laminated to the planar surface 294 of thesecond non-apertured film 298. It is to be understood that thisembodiment can be made without the nonwoven material 300 adheredthereto.

It is to be understood that each of the laminating materials cancomprise further layers including nonwoven materials on either theplanar or three-dimensional sides of the films.

Combinations of laminated materials can be created which are useful innumerous commercial products to fill currently unmet consumer needs. Forexample, the composite film in FIG. 3 provides a barrier film having adull soft surface suitable for disposable and medical products. Thecomposite film shown in FIG. 4 provides similar barrier properties andshows a film having a soft high loft apertured side. The composite filmshown in FIG. 5 is especially useful for bubble packaging materials fordelicate and expensive components. The composite film shown in FIG. 6 isalso useful for bubble packages to provide physical protection whereinat least one of the films can be a barrier type film for use in shelflife extension of food and other items. The composite film shown in FIG.7 is especially useful in disposable products applications, wherein abarrier film is needed and wherein a feeling of softness and dullness isprovided by the apertured film. The composite film shown in FIG. 8 isespecially useful in applications for a feminine product topsheetutilizing a dual aperture size concept in having a greater embosseddepth. Alternatively, the film is useful in other applications requiringa larger initial pore or aperture size which overlays a smaller aperturesize. The composite film shown in FIG. 9 is useful for any applicationwhich requires a larger embossed thickness, possibly for fluid storageor layer separation with a finer top cover for tactile and visualeffects. One especially useful application is useful for a diaperbacksheet. The composite film of FIG. 10 is useful to replace currentlyused, but expensive, nonwoven materials. The composite film shown inFIG. 10 has a soft three-dimensional side of the film as an outersurface. The composite film shown in FIG. 11 provides a furtherembodiment of bubbled film products wherein the microprotuberances canhave different configurations. FIG. 11 provides a barrier film having ahigh loft and dull surface suitable for disposable and medical products.

It is to be understood that there are many other composite films thatcan be formulated using the method of the present invention. Whileparticular embodiments of the present invention have been illustratedand described, it will be obvious to those skilled in the art thatvarious changes and modifications can be made without departing from thespirit and scope of the invention and it is intended that the claimsherein cover all such modifications that are within the scope of thisinvention.

We claim:
 1. A method for the manufacture of a laminated composite filmcomprising:a) supplying at least one layer of a first thermoplasticmaterial at a sufficiently elevated temperature and at a sufficient massin order to achieve a bond between the first material and a secondmaterial, the first material having a top surface and a bottom surface;b) passing successive portions of the first material into contact with acontinuous moving perforated member having perforations which extendthrough the perforated member, subjecting the bottom surface of thefirst material to the action of a fluid pressure differential, the fluidpressure differential causing portions of the first material to flowinto the perforations of the continuous moving perforated member; c)maintaining the fluid pressure differential for a period of timesufficiently for a plurality of microprotuberances to be formed in thefirst material, the microprotuberances having a thickness and mass thatare less than a thickness and mass of the material forming the topsurface of the first material; d) supplying at least one layer of thesecond material comprising a thin, thermally sensitive thermoplasticmaterial, the second material having a top surface and a bottom surfacesuch that the top surface or the bottom surface of the second materialis brought into contact with the top surface of the first material afterthe protuberances have been formed in the first material, wherein thesecond material laminates or adheres to the first material withoutsubstantially distorting the first material or the second material; and,e) continuously removing the laminated first and second materials fromthe moving perforated member.
 2. The method of claim 1, wherein thesecond material is brought into contact with the first material underpressure sufficient to laminate the bottom surface of the secondmaterial onto the top surface of the first material without distortingthe first material or second material.
 3. The method of claim 1, whereinthe pressure differential comprises a negative or vacuum pressureapplied to the bottom surface of the first material as the firstmaterial moves over a portion of the moving perforated member.
 4. Themethod of claim 1, wherein the first material has a plurality ofapertures extending therethrough.
 5. The method of claim 1, wherein thepressure differential cools the first material as the second material islaminated to the first material.
 6. The method of claim 1, wherein thesecond material comprises at least one layer of an aperturedthree-dimensional polymeric film, the bottom surface of the secondmaterial defining a plurality of microprotuberances having distal endswhich have a thickness and mass that are less than a thickness and massof the material forming the top surface of the second material.
 7. Themethod of claim 1, wherein the second material comprises at least onelayer of a non-apertured three-dimensional polymeric film, the bottomsurface of the second material defining a plurality ofmicroprotuberances having distal ends which have a thickness and massthat are less than a thickness and mass of the material forming the topsurface of the second material.
 8. The method of claim 1, wherein thesecond material is heated at a point prior to lamination of the secondmaterial onto the first material.
 9. The method of claim 1 in which thefirst material has a first, effective thickness and the second materialhas a second effective thickness, the method further comprisingsupplyingthe second material onto the first material at a distance that is lessthan the combined first and second effective thicknesses of the firstand second materials; and, passing the laminated first and secondmaterials through a gap at a point of interface, the gap being definedbetween the continuous moving perforated member and the second materialdispensing means, whereby the combined effective thicknesses of thelaminated first and second materials are reduced.
 10. The method ofclaim 9, in which the gap has a length that ranges from about 50% toabout 99% of the combined first and second effective thicknesses of thefirst material and the second material.
 11. The method of claim 10, inwhich the gap has a length that ranges from about 75% to about 95%.